Garment boning member or stay



Oct. 4, 1966 w. M. JONAS 3,276,041

GARMENT BONING MEMBER 0R STAY Filed Jan. 17, 1966 ATTORNEY United StatesPatent O 3,276,041 GARMENT BONING MEMBER R STAY Walter M. Jonas, Easton,Pa., assignor to Maid-Rite Wire Products Corp., Long Island, N.Y., acorporation of New York Filed Jan. 17, 1966, Ser. No. 520,930 3 Claims.'(Cl. 2--258) This is a continuation-in-part of my pending applicationfor United States Letters Patent Serial No. 328,425, filed December 5,1963, now abandoned.

This invention relates generally to stiifening and shaping members ofthe type usually employed in undergarments, such as, brassieres,girdles, corsets and the like, and more particularly known as boningmembers or stays.

Various types of boning members or stays have been used in theundergarment trade. Among these existing types, have been boning membersor stays formed of elongated, at strips of spring metal, whale bone,celluloid or other resilient plastic material which normally lie in aiiat plane and are capable of ilexing only in the direction normal tothat plane, that is, about the laterally extending axes of theircross-sectional areas. Where it is desired to provide ilexing of theboning member or stay within the flat plane in which the latter normallylies as well as in directions perpendicular to that Hat plane, theundergarment or foundation industry has accepted as the standard forsuch use a boning member having a body portion of high carbon steel wireformed into a zig-zag or continuous sinusoidal shape, or into aflattened spiral shape, with the ends of the steel wire body beingencased in metal or plastic tips, for example, as shown in US. PatentNo. 2,908,913 and No. 3,020,557, issued October 20, 1959 and February13, 1962, respectively, to Morton Sobel. Although the spirally wound orzig-zag shaped wire body of such a boning member is capable of flexingin its normal at plane as well as in directions perpendicular to thatplane, such a boning member is relatively expensive by reason of itsmulti-part construction, relatively heavy and further presents rough oruneven longitudinal edges which frequently interfere with the insertionof the boning member or stay into the fabric pocket provided in theundergarment for receiving the same. The caps or tips at the ends of thewire body do become separated from the latter, in which case the sharpwire ends jab the wearer and cause acute discomfort. The steel wireforming the resiliently flexible body of the boning member also tends torust or corrode, particularly when the undergarment is subjected torepeated laundering, and rust from the boning member stains or discolorsthe fabric of the undergarment. Further, the wire frequently has oil oranother coating thereon, which dirties the hands of the personsinserting the boning members into garments and thus soils the latter.

Although it has been proposed, for example, in U.S. Patent No.3,030,633, to provide a plastic boning member which can ex laterally inthe normal flat plane by providing the side edges thereof with staggeredV-shaped notches, such notched side edges interfere with `the insertionof the boning member into the fabric pocket provided therefor in theundergarment and do not approximate the flexural characteristics of thepreviously mentioned standard boning members accepted by the foundationor undergarment trade. Further, plastic boning members formed of threeor more longitudinal, laterally spaced rod-like plastic elementsconnected to each other by staggered, spaced bridging members, as inU.S. Patent No. 3,037,211, have not beeen satisfactory in use, in thatsuch boning members also do not provide the desired ratio of flexibilityin the normal at plane to flexibility perpendicular to such plane, andare relatively expensive to produce.

Patented Oct. 4, 1966 ICC Accordingly, it is an object of the presentinvention to provide a yone-piece boning member or stay molded of aplastic having a high exural modulus, and which, in use, has operatingcharacteristics, as concerns flexing and the like, corresponding tothose of Athe standard boning members disclosed in the previouslyidentified U.S. Patents No. 2,908,913 and No. 3,020,557, while beingrelatively inexpensive to produce and avoiding the above mentioneddisadvantages of such standard boning members.

In accordance with an aspect of this invention, a onepiece, moldedboning member of a plastic material having a exural modulus of at leastapproximately 400,000 p.s.i. at room temperature, comprises anelongated, normally flat body of an overall width approximately 4 timesits thickness and having straight, smooth side edges extendingsubstantially along the length of the body, and such body has solid endportions and longitudinal slot means extending through the body parallelto its side edges between the end portions and dividing eachcorresponding portion of the body into two laterally uniformly spaced,elongated elements of uniform cross-section having predetermined ratiosof thickness =to width, spacing and length so as to achieve the desiredflexural characteristics.

It has been found that the desired llexu-ral characteristics of thedescribed boning member are achieved only when each of its elongatedelementshas a ratio of thickness to width of approximatey 4:5 with alateral spacing between the elements which is in the range between l to11/2 times the Width of each element, and when the elongated elementsextending along at least the middle half of the body each have a lengthlying in the range between approximately 16 times the width of theelement and 63 rtimes the thickness of the element.

The above, and other objects, features and advantages of the invention,wiill be apparent in the lfollowing detailed description of illustrativeembodiment thereof which is to be read in connection with theaccompanying drawing forming a part hereof, and wherein:

FIG. 1 is a fragmentary elevational view, partly broken away, `showiingthe manner in which a boning member embodying this invention isincorporated in a garment;

FIG. 2 is an enlarged elevational View of the boning member of FIG. l;

FIG. 3 is a side elevational view of the boning member of FIG. 2;

FIGS. 4 and 5 are enlarged sectional views taken along the lines 4 4 and5 5, respectively, on FIG. 2;

FIG. 6 iis a view similar to that of FIG. 2, but illustrating lateralflexing of the boning member; and

FIGS. 7 and S are further views similar to that of FIG. 2, but showingother embodiments of the invention.

Referring to the drawing in detail and initially to FIGS. 2 and 3, itwill be seen that a boning member or stay embodying this invention, andthere generally identified by the reference numeral 10, is of one-piececonstruction and is preferably molded of a plastic material having aflexural modulus of at least approximately 400,000 p.s.i. at roomtemperature. The plastic material employed is preferably Delrin, thatis, superpolyoxymethylene having a molecular weight of at least 15,000,but other plastic materials having the requisite high flexural modulimay be used, `such as, the acetal resin available from General Electricunder the tradename Celcon.

The one-piece boning member 10 consists of an elongated body lof uniformoverall Width Wa and thickness T (FIG. 4) along substantially its entirelength (FIGS. 2 and 3), with the overall width Wa being approximately 4times the thickness T so that, while the boning member or stay 10normally tends to lie in a at plane, as indicated in f-ull lines on FIG.3, it is free to flex o-r bend out of that plane, as indicated in brokenlines at 10 on FIG. 3 by reason of the relatively small thickness T ofmaterial resisting bending out of the ilat plane. The elongated body ofhoning member has straight longitudinal or side edges 11 extending4along substantially the entire length of the honing member and thentapering into smoothly curved or rounded end edges 12.

Lateral ilexing of honing member 10, that is, flexing of the honingmember in the normally ilat plane thereof, is made possible by providingthe elongated body of the honing member with at least one longitudinalslot 13 extending therethrough parallel to the side edges 11 andterminating short of the ends of the honing member to divide the body,between the end portions 14 thereof, into laterally spaced, elongatedelements 15. As shown on FIG. 5, the end portions 14 preferably taper inthickness toward the end edges and each have a 4length l from 1%. to 2times the overall width Wa of the body.

The honing member 10 is intended to be incorporated in an undergarment16 (of which a portion is illustrated on FIG. 1), such as, a hrassiere,girdle, corset or the like. The honing member 10 is received or sheathedin a pocket 17 formed by a fabric strip stitched to the body of thegarment. In practice, the fabric stripris usually stitched to thegarment along the two longitudinal edges and one end of the strip, sothat the resulting pocket is open at one end for reception of the honingmember. The rounded en-d edges 12 and the tapering of end portions 14 ofthe honing member 10 and the smooth, straight side edges 11 greatlyfacilitate insertion of the latter in the pocket 17 by ensuring thatthere are no rough edges or indentations lsusceptible of catching on themouth of the pocket. After the honing member 10 has been inserted in thepocket 17, the open end of the latter is stitched closed. In order tofurther secure the Ahoning member within the pocket 17, a line ofstitching 18, for example, the stitching of a hem 19 along an edge ofthe garment, may be passed through an end portion 14 of the honingmember. Passage of the stitching 18 through the end portion 14 of thehoning member is made possible by selection of the plastic material ofthe latter, and is further facilitated by the described tapering orreduction of thickness of the honing member at the end portions 14thereof.

In accordance with this invention, each of the elongated elements has aratio of its thickness T `to its Width We of approximately 4:5 and thelateral 'spacing between the elements 15, as defined by the Width Ws ofslot 13 (FIG. 4) .is in the range between 1 to 11/2 times the elementwidth We. Thus, in an illustrative example of a honing member inaccordance with the invention, the thickness T of the body, and hence ofeach element 15, is 0.060, the width We of each element is 0.075" andthe slot width Ws or spacing between the elements 15 is 0.095", givingan overall Width Wa of 0.245".

Further, in accordance with the invention, the length L (FIG. l) of slot13, and hence the length of each element 15, lies in the range betweenapproximately 16 times the element width We and 63 times the elementthickness T. Thus, in the specific example of element Width andthickness given above, the length L of each element 15 may be between aminimum of 1.20" and a maximum of 3.78.

The effect of the .foregoing ratios of element width, thickness, spacingand length is to ensure that the honing member 10 when installed in thepocket 17 securely resists longitudinally directed forces, as -indicatedby the arrows F on FIG. 1, for example, the tendency of the hem 19 whichmay form the upper margin of a corset or girdle, to creep downwardly,and yet, be capable of the desired degrees of exihle, both laterally inits normal flat plane and in directions perpendicular toy that plane soas to follow the body movements of the wearer land thereby affordmaximum comfort to the latter.

As shown on FIG. 6, when the honing member 10 is subjected to `lateralexing by body movements of the wearer, the elongated element 15 at theinside of the curvature bends more sharply than the other elongatedelement 15 and therefore moves laterally across the slot 13 toward thelatter.

It is to be understood that honing members or stays embodying thisinvention may he provided with only a single longitudinal slot, as at 13on FIGS. 2 and 6, or with a plurality of end-to-end arrangedlongitudinal slots effective to divide the respective portions of thebody of the honing member linto laterally spaced elongated elementswhich are free to move laterally relative to each other during lateralflexing of the honing member. As more particularly shown on FIG. 7, ahoning member or stay 10a embodying this invention lmay be formed withtwo longitudinal slots 13a in end-to-end, spaced apart relationshipbetween the end portions 14a. Thus, the end portions 14a of the honin-gmember are connected by elongated elements 15a which, as before, arelaterally spaced apart so as to be free to flex or move laterallyrelative to each other. In accordance with this invention, the elements15a -have the ratios of width, thickness, spacing and length mentionedabove with respect to the honing member 10 so as to provide therequisite ratios of flexing laterally 'in the normal ilat plane and o'fflexing perpendicular to that plane, and also to provide the necessaryresistance to movement of end portions 14a toward each other. When thehoning member 10a -is subjected to lateral ilexin-g, the elongatedelements 15a at the inside of the curve or bend are bent more sharplythan the corresponding outer elongated elements and move laterallytoward the latter across the intervening slots 13a. Although there is arelatively rigid connection 16a between the opposite sides of the honingmember 10a at the middle of the latter, such rigid connection does notsubstantially interfere with the relative movements of the elongatedelements 15a between the middle of the honing member and the endportions 14a of the latter. In order to ensure that the rigid connection16a does not unduly restrict lateral flexing of the honing member 10a,such rigid connection 16a must have a length along the honing memberthat does not substantially exceed the overall width Wa of the honingmember.

Referring now to FIG. 8, it will be seen that a still longer honingmember or stay 10b in accordance with this invention may be formed withfour longitudinal slots 13b and 13b in end-to-end, spaced apartrelationship between the end portions 14h. Thus, t-he end porhions 1412are connected by elongated elements 15b and 15b spaced apart by therespective slots 13b and 13'b so as to he .free `to flex or movelaterally relative to each other. Where the honing member has more thantwo slots, as in FIG. 8, at least the elongated elements 15b whichextend along the -middle half of the honing member have ratios of width,thickness, spacing and length L as specified above in connection withthe honing memher 10, Whereas the remaining elongated members 15b haveratios of width, thickness and spacing, as previously specilied, but mayhave lengths L' that .are shorter than the previously mentioned minimumof 16 times the width of each element 15b. In all cases, the rigidconnections 16h between slots 13b and the rigid connections 16b betweenthe adjacent ends of slots 13b and 13'b preferably have lengths that donot substantially exceed the overall Width of the honing member.

It will be apparent that honing members -or stays embodying thisinvention, being of one-piece construction and formed of plasticmaterial, will be inexpensive, light in weight, and perfectly clean andlcorrosion resistant, all of which are desirable characteristics forincorporation in undergannents of the described character. Further, thetapering and .rounded or curved end portions 14, 14a or 1412, beingformed integrally with the remainder of the honing member, cannot becomesepara-ted therefrom, even under severe usa-ge, and thereby avoid thepreviously mentioned disadvantageous tendency of the caps or tips toseparate from the zig-zag or flat spirally wound spring wire bodies ofthe only existing laterally flexible boning members of comparablecharacteristics.

Although illustrative embodiments of this invention have been describedin detail herein with reference to the accompanying drawing, it is to beunderstood that the invention is not limited to those preciseembodiments, and that various changes and modifications may be effectedtherein by one skilled in the art without departing from the sc-ope orspinit Iof the invention, except as dened in the appended claims.

What is claimed is:

1. A one-piece, molded boning member of a plastic material having ailexural modulus of at least approximately 400,000 p.s.i. at roomtemperature, comprising an elongated, normally at body having athickness of approximately 0.060 inch, said body having an overall widthapproximately 4 times its thickness and having straight, smooth sideedges extending substantially along the Ilength of said body, said bodyhaving solid end portions and longitudinal slot means extending throughsaid body parallel to said side edges between said end portions, saidslot means dividing each corresponding portion of the body into twolaterally uniformly spaced, elongated elements lof uniform cross-sectionand each having a ratio of thickness to width of approximately 4:5 witha lateral spacing between said elements which is in the range between 1to 11/2 times said widths thereof, the elongated elements extendingalong at least the middle half of said body each having a length lyingin the range between approximately 16 times said width of each elementand 63 times said thickness of each element so as to permit lateralexing of the boning member in its normal flat plane and flexing of theboning member out oi said plane while adequately resisting substantialmovement of said end portions toward each other.

2. A boning member according to claim 1; wherein said slot meansconsists of a single slot extending through said body un-interruptedlybetween said end portions thereof.

3. A honing member according to claim 1; wherein said slot meansconsists of `a plurality of slots extending throu-gh said body inend-tofend, :longitudinally spaced relationship between said endportions, and -the spacing between adjacent ends of said slots is notsubstantially greater than said overall width ofthe body.

References Cited by the Examiner UNITED STATES PATENTS 394,746 12/ 1888Williamson 2-259 469,619 2/ 1892 Weldon 2-264 766,630 8/1904 Kops 2-259913,435 2/1909 Schloss 2-134 2,710,967 6/1955 Bohm 2--260.1 2,908,91310/ 1959 Sobel 2-260 3,020,557 2/ 1962 Sobel 2-260 3,030,633 4/1962Chalfin 2-258 3,037,211 6/1962 Bohm 2-256 FOREIGN PATENTS 9,487 1885Great Britain.

JORDAN FRANKLIN, Primary Examiner.

A. R. GUEST, Assistant Examiner.

1. A ONE-PIECE, MOLDED BONING MEMBER OF A PLASTIC MATERIAL HAVING AFLEXURAL MODULUS OF AT LEAST APPROXIMATELY 4008000 P.S.I. AT ROOMTEMPERATURE, COMPRISING AN ELONGATED NORMALLY FLAT BODY HAVING ATHICKNESS OF APPROXIMATELY 0.060 INCH, SAID BODY HAVING AN OVERALL WIDTHAPPROXIMATELY 4 TIMES ITS THICKNESS AND HAVING STRAIGHT, SMOOTH SIDEEDGES EXTENDING SUBSTANTIALLY ALONG THE LENGTH OF SAID BODY, SAID BODYHAVING SOLID END PORTIONS AND LONGITUDINAL SLOT MEANS EXTENDING THROUGHSAID BODY PARALLEL TO SAID SIDE EDGES BETWEEN SAID END PORTIONS, SAIDSLOT MEANS DIVIDING EACH CORRESPONDING PORTION OF THE BODY INTO TWOLATERALLY UNIFORMLY SPACED, ELONGATED ELEMENTS OF UNIFORM CROSS-SECTIONAND EACH HAVING A RATIO OF THICKNESS TO WIDTH OF APPROXIMATELY 4:5 WITHA LATERAL SPACING BETWEEN SAID ELEMENTS WHICH IS IN THE RANGE BETWEEN 1TO 11/2 TIMES SAID WIDTHS THEREOF, THE ELONGATED ELEMENTS EXTENDINGALONG AT LEAST THE MIDDLE HALF OF SAID BODY EACH HAVING A LENGTH LYINGIN THE RANGE BETWEEN APPROXIMATELY 16 TIMES SAID WIDTH OF EACH ELEMENTAND 63 TIMES SAID THICKNESS OF EACH ELEMENT SO AS TO PERMIT LATERALFLEXING OF THE BONING MEMBER IN ITS NORMAL FLAT PLANE AND FLEXING OF THEBONING MEMBER OUT OF SAID PLANE WHILE ADEQUATELY RESISTING SUBSTANTIALMOVEMENT OF SAID END PORTIONS TOWARD EACH OTHER.